Free Aerospace Lab Technician Destructive Testing course (6 months)

Aerospace Lab Technician Destructive Testing:

Brief Job Description: Aerospace Lab Technician Destructive Testing is responsible for identifying the test sample/ components, identify the test methods, prepare the test samples, set the equipment & test setup, carryout the test & observe the test result as per the requirement.

Personal Attributes: The individual should have basic communication ability and should be responsible in order to maintain procedures. He should have the ability to work for long hours and be cautious to avoid any accidents.

Different types of destructive testing as per aerospace standards:-

Performance Criteria:

Pre-testing sample & equipment verification activities

PC1. verify the test information from test request (like sample identification, sample materials, sample dimension, test type, test method etc.)

PC2. verify the test sample physical condition and sample packing condition

PC3. ensure the test type requested are feasible to test, all the relevant test information are reflected on test request & sample visual condition are satisfactory to accept the test request Aerospace Lab Technician Destructive Testing

PC4. ensure that the testing equipment is in good working condition and necessary external power available for operating the equipment

PC5. ensure that testing equipment has valid calibration certificate

PC6. ensure the laboratory environment condition (temperature & relative humidity) are as per test requirements

PC7. ensure the test fixtures applicable for the test are in good condition and having valid certification as applicable

PC8. interpret the test specification and test procedure so that the test can be performed as per requirement.

Performing different types of destructive testing:-

PC9. ensure the test specimen details (like: test ref no., material name, batch no., test specification reference etc.) are entered on the testing software

PC10. cross verify the test specimen dimensions by Vernier caliper/micrometer as per test request and enter the same on testing software

PC11. place or fix the test specimen on the test fixtures as per the relevant test procedure or work instruction Aerospace Lab Technician Destructive Testing

PC12. align the test samples on the test fixtures as per sketches and instructions provided on test procedure. Use additional alignment fixtures if applicable

PC13. ensure all the test samples are tested as per test request and completion of the test.

PC14. note down if any discrepancy noticed during test against test request number.

Report preparation activities post testing Aerospace Lab Technician Destructive Testing:

PC15. print report of the statistical data for the particular test number with all individual sample value and average value. Print test graphs if applicable

PC16. cross verify the test result calculation (like stress value) manually with the printout software calculation report and is in compliance with the test procedure Aerospace Lab Technician Destructive Testing

PC17. visually examine the tested sample failure mode as applicable and record against individual test sample

PC18. preserve the tested samples with proper identification and packing for the period as specified in the laboratory procedure / guidelines

PC19. Provide verdict of the test results based on a comparison of the measured test results and failure mode with the acceptance criteria. Ensure In-case of non- availability of acceptance criteria the results are reported without giving any verdict

PC20. ensure the test reports are coordinated by authorised testing personnel and finally released with coordination from authorised test report signatory Aerospace Lab Technician Destructive Testing

PC21. ensure that laboratory maintains one copy of the completed test reports in addition to the test reports released to the concerned personnel

PC22. report relevant observations and remarks in case of deviation in test values as per understanding or report the same to lab-in-charge PC23. ensure repeat test is carried out as per applicable test procedure with duly concurrence from lab-in-charge, in case of test samples does not meet the requirements Aerospace Lab Technician Destructive Testing

PC24. ensure that additional sample are collected and preserved for quality check re-testing as applicable for laboratory procedure / guidelines.

Knowledge and Understanding:

Organisational Context

KA1. relevant standards and procedures followed in the company

KA2. different types of products manufactured by the company Aerospace Lab Technician Destructive Testing

KA3. quality norms and standards prescribed in the quality manual by the organisation

KA4. process flow/ routing of components in the organisation Aerospace Lab Technician Destructive Testing

KA5. personnel and other HR policies of the organisation Aerospace Lab Technician Destructive Testing

Technical Knowledge

KB1. aerospace manufacturing standard and procedures such as ISO 9001, AS9100, etc

KB2. different types of destructive / mechanical testing for composite processes (like: Tensile, Compression, Adhesion, Inter-laminar, Lap Shear, Flexural etc.)

KB3. different types of destructive / mechanical test equipment (like Isod, UTM, Charpy, Rockwell, Brinell etc).

KB4. different types of test fixtures, test items, supporting tools used in the destructive testing process and their identification

KB5. basic fundamentals of machines, mechanics, strength of materials & physics Aerospace Lab Technician Destructive Testing

KB6. test environment conditions applicable for various test such as stress test, hardness test, metallographic test etc

KB7. to read machine drawing, fixture drawings, test sample drawings to create the output as required

KB8. different types of composite raw materials applicable for various Aerospace Lab Technician Destructive Testing

KB9. preparation of test specimens (or traveler coupons) for testing from various composite raw materials

KB10. periodic preventive maintenance and calibration activities of the test equipment & test fixtures

KB11. test fixtures setup and test samples alignment as applicable for testing

KB12. storage conditions required for each test samples before and after testing

KB13. methods of using instruments like Vernier callipers, micrometres, rulers etc. for test sample measurements

KB14. test report preparation, verdict of test results as per acceptance criteria Aerospace Lab Technician Destructive Testing

KB15. retest and repeat test procedure in case of test sample failure

KB16. test method & test result validation by applicable quality checks

KB17. different failure modes as applicable for various tests used for examining materials samples

KB18. ISO/IEC 17025, NABL system requirements & AS 9100 QMS requirements

KB19. basic uses of computer system, MS-Word & Excel, Testing software’s & information systems like ERP packages etc.

Core Skills/ Generic Skills Aerospace Lab Technician Destructive Testing

Writing Skills SA1. write test information from the manuals, discussion notes, process charts, test procedure & other governing documents etc. SA2. create small notes/ work documents/ diagram/ maps for self-help to understand the testing process Reading Skills The user/individual on the job needs to know and understand how to: SA3. read equipment manuals and process documents to understand the equipment and processes better SA4. read internal information memos sent by internal customers (other functions within the organisation) SA5. read & interpret work instruction, photos/ symbols given on equipment and work areas SA6. read machine drawings/ engineering drawings, test sample sketches etc. Oral Communication (Listening and Speaking skills) Aerospace Lab Technician Destructive Testing The user/individual on the job needs to know and understand how to: SA7. discuss task lists, schedules, and work-loads with the test engineer/ lab in-charge SA8. answer the queries raise by the test engineer/ lab-in-charge as well as other departments, internal customer SA9. attentively listen with full attention to the speaker and comprehend the information given by the speaker on various testing process & lab management SA10. effectively communicate information to team members in the lab and concerned functions about testing activity   Professional Skills   Plan and Organise Aerospace Lab Technician Destructive Testing   The user/individual on the job needs to know and understand how to: SB1. persuade team members to wear the personal protective equipment as per the requirement SB2. ensure that the team understands the importance of using various machines/equipment without creating any risk to human/machine     Critical Thinking Aerospace Lab Technician Destructive Testing   The user/individual on the job needs to know and understand: SB3. analyse, evaluate and apply information gathered from observation, experience, reasoning or communication to act efficiently     Aerospace Lab Technician Destructive Testing Problem Solving   The user/individual on the job needs to know and understand how to: SB4. recognise a work place problem or a potential problem and take action SB5. determine problems needing priority action SB6. gather information and provide assistance as required to solve problems SB7. refer problems outside area of responsibility to approach person SB8. make decisions in emergency conditions in case of supervisor are not available   Analytical Aerospace Lab Technician Destructive Testing Skills   The user/individual on the job needs to know and understand how to: SB9. analyse best possible solutions (cost, time, effort, etc.) suited for operations Critical Thinking Skills The user/individual on the job needs to know and understand how to: SB10. concentrate on task at hand and complete it without errors SB11. apply balanced judgments to different situations Organisation safety and security procedures: Performance Criteria   Comprehending the safety and security procedures   PC1. comply with the organisation’s safety and security policies and procedures PC2. comply with the regulatory guidelines on safe conduct of operations and maintenance of conditions to thwart any acts of unlawful interference PC3. report any identified breaches of safety and security policies and procedures to the designated person PC4. report any theft of organisation property according to the organisation policy PC5. coordinate with other resources at the workplace (within and outside the organisation) to achieve a safe and secure environment PC6. identify and mitigate any safety and security hazards like illness, accidents, fires or acts of unlawful interference if it falls within the limits of the individual’s authority PC7. report any hazards outside the individual’s authority to the relevant person in line with organisational procedures and regulatory guidelines PC8. follow the organisation’s emergency procedures for accidents, fires or acts of unlawful interference PC9. identify and recommend opportunities for improving health, safety, and security to the designated person PC10. ensure that all health and safety records are updated and procedures are well defined     Knowledge and Understanding     Organisational context   KA1. hazard identification and risk management as defined within the organisational policy and procedures KA2. legislative requirements and organisation’s procedures for maintenance of safety and security standards and individual’s role and responsibilities in relation to this KA3. how and when to report hazards KA4. the limits of responsibility for dealing with hazards KA5. the organisation’s emergency procedures for different emergency situations and the importance of following these KA6. the importance of maintaining high standards of safety and security KA7. implications that any non-compliance with safety and security may have on individuals and the organisation     Technical Knowledge KB1. different types of breaches of safety and security and how and when to report these KB2. evacuation procedures for workers KB3. how to summon medical assistance and the emergency services, where necessary KB4. how to use the health, safety and accident reporting procedures and the importance of these KB5. regulatory guidelines on dealing with safety and security emergencies     Core Skills/ Generic Skills   Writing Skills The user/ individual on the job needs to know and understand how to: SA1. complete accurate, well written report in English language detailing the situations of emergency with attention to detail   Reading Skills The user/individual on the job needs to know and understand how to: SA2. read instructions, guidelines/procedures/rules   Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA3. listen to and orally communicate information with all concerned     Professional Skills   Decision Making   The user/individual on the job needs to know and understand how to: SB1. make decisions on a suitable course of action or response if permitted by the authority matrix     Aerospace Lab Technician Destructive Testing Plan and Organise   The user/individual on the job needs to know and understand how to: SB2. monitor efficient functioning of all activities SB3. plan and organise work to achieve targets and deadlines     Customer Centricity   The user/individual on the job needs to know and understand how to: SB4. communicate with customers in a courteous manner SB5. maintain effective relationship with the customers     Problem Solving   The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes fo r errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors     Analytical Thinking   The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc) suited for operations   Critical Aerospace Lab Technician Destructive Testing Thinking  The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand an d complete it without errors SB10. apply balanced judgments to different situations       Maintain 5S at the work premises   Performance Criteria   Ensure sorting PC1. follow the sorting process and check that thetools, fixtures & jigs that are lying on workstations are the ones in use and un- necessary itemsare not cluttering the workbenches or work surfaces. PC2. ensure segregation of waste in hazardous/ non hazardous waste as per the sorting work instructions PC3. follow the technique of waste disposal and waste storage in the proper bins as per SOP PC4. segregate the items which are labeled as red tag items for the process area and keep them in the correct places PC5. sort the tools/ equipment/ fasteners/ spare parts as per specifications/ utility into proper trays, cabinets, lockers as mentioned in the 5S guidelines/ work instructions PC6. ensure that areas of material storage areas are not overflowing PC7. properly stack the various types of boxes and containers as per the size/ utility to avoid any fall of items/ breakage and also enable easy sorting when required PC8. return the extra material and tools to the designated sections and make sure that no additional material/ tool is lying near the work area PC9. follow the floor markings/ area markings used for demarcating the various sections in the plant as per the prescribed instructions and standards   Ensure proper documentation and storage PC10. Follow the proper labeling mechanism of instruments/ boxes/ containers and maintaining reference files/ documents with the codes and the lists PC11. Check that the items in the respective areas have been identified as broken or damaged PC12. follow the given instructions and check for labeling of fluids, oils. lubricants, solvents, chemicals etc. and proper storage of the same to avoid spillage, leakage, fire etc. PC13. make sure that all material and tools are stored in the designated   Ensure cleaning of self and the work place PC14. check whether safety glasses are clean and in good condition PC15. keep all outside surfaces of recycling containers are clean Aerospace Lab Technician Destructive Testing PC16. ensure that the area has floors swept, machinery clean and generally clean. In case of cleaning, ensure that proper displays are maintained on the floor which indicate potential safety hazards PC17. check whether all hoses, cabling & wires are clean, in good condition and clamped to avoid any mishap or mix up PC18. ensure workbenches and work surfaces are clean and in good condition PC19. follow the cleaning schedule for the lighting system to ensure proper illumination PC20. store the cleaning material and equipment in the correct location Aerospace Lab Technician Destructive Testingand in good condition PC21. ensure self-cleanliness – clean uniform, clean shoes, clean gloves, clean helmets, personal hygiene Ensure sustenance PC22. follow the daily cleaning standards and schedules to create a clean working environment PC23. attend all training programs for employees on 5S PC24. support the team during the audit of 5S PC25. participate actively in employee work groups on 5S and encourage team members for active participation PC26. follow the guidelines for What to do and What not to do to build sustainability in 5S as mentioned in the 5S check lists/ work instructions   Knowledge and Understanding Organisational Context KA1. relevant standards, procedures and policies related to 5S followed in the company   Technical Knowledge KB1. have basic knowledge of 5S procedures KB2. know various types 5s practices followed in various areas KB3. understand the 5S checklists provided in the department/ team KB4. have skills to identify useful & non useful items KB5. have knowledge of labels , signs & colours used as indicators KB6. Have knowledge on how to sort and store various types of tools, equipment, material etc. KB7. know , how to identify various types of waste products KB8. understand the impact of waste/ dirt/ dust/unwanted substances on the process/ environment/ machinery/ human bodyKB9. have knowledge of best ways of cleaning & waste disposal KB10. understand the importance of standardisation in processes KB11. understand the importance of sustainability in 5S KB12. have knowledge of TQM process KB13. have knowledge of various materials and storage norms KB14. understand visual controls, symbols, graphs etc.   Core Skills/ Generic Skills Writing Skills The user/ individual on the job needs to know and understand how to: SA1. write basic level notes and observations SA2. note down observations (if any) related to the process SA3. write information documents Aerospace Lab Technician Destructive Testing to internal departments/ internal teams Reading Skills The user/individual on the job needs to know and understand how to: SA4. read 5S instructions put up across the plant premises Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA5. effectively communicate Aerospace Lab Technician Destructive Testing information to team members inform employees in the plant and concerned functions about 5S SA6. question the process head in order to understand the 5S related issues SA7. attentively listen with full attention and comprehend the information given by the speaker during 5S training programs   Professional Skills Judgmental Thinking The user/individual on the job needs to Aerospace Lab Technician Destructive Testing know and understand how to: SB1. use common sense and make judgments during day to day basis SB2. use reasoning skills to identify and resolve basic problems using 5S Persuasion The user/ individual on the jobs needs to know and understand how to: SB3. persuade co team members to follow 5 S SB4. ensure that the co team members understand the importance of using 5S tool Creativity The user/individual on the job needs to know and understand how to : SB5. use innovative skills to perform and manage 5S activities at the work desk and the shop floor SB6. exhibit inquisitive behaviour to Aerospace Lab Technician Destructive Testing seek feedback and question on the existing set patterns of work Self –Discipline The user/individual on the job needs to know and understand how to: SB7. do what is right, not what is a popular practices SB8. follow shop floor rules & regulations and avoid deviations; make 5S an integral way of life SB11. ensure self-cleanliness on a daily basis SB12. demonstrate the will to keep the work area in a clean and orderly manner   Work effectively in a team Performance Criteria Support the work team PC1. display courteous and helpful behaviour at all times PC2. take opportunities to enhance the level of assistance offered to colleagues PC3. meet all reasonable requests for assistance within acceptable workplace timeframes PC4. complete allocated tasks as assigned PC5. seek assistance when difficulties arise PC6. use questioning techniques to clarify instructions or responsibilities, PC7. identify and display a non-discriminatory attitude in all contacts with customers and other staff members   Maintain personal presentation PC8. observe appropriate dress code and presentation as required by the workplace, job role and level of customer contact PC9. follow personal hygiene procedures according to organisational policy   Develop effective work habits PC10. interpret, confirm and act on workplace information, instructions and procedures relevant to the particular task PC11. interpret, confirm and act on legal requirements with regards to anti- discrimination, sexual harassment and bullying PC12. ask questions to seek and clarify workplace information PC13. plan and organise daily work routine within the scope of the job role PC14. prioritise and complete tasks according to required timeframes PC15. identify work and personal priorities and achieve a balance between competing priorities Organisational Context KA1. policies and procedures relating to the job role KA2. the value system of the organisation KA3. employee rights and obligations   Technical Knowledge KB1. ask questions to identify and confirm requirements KB2. follow routine instructions through clear and direct communication KB3. use language and concepts appropriate to cultural differences KB4. use and interpret non-verbal communication KB5. the scope of information or materials required within the parameters of the job role KB6. consequences of poor team participation on job outcomes KB7. work health and safety requirements   Core Skills/ Generic Skills Writing Skills, On the job the individual needs to be able to: SA1. complete documentation accurately SA2. write simple reports when required Reading Skills On the job the individual needs to be able to: SA3. read information accurately SA4. read and interpret data sheets Oral Communication (Listening and Speaking skills) The user/individual on the job needs to know and understand how to: SA5. listen to and orally communicate information with all concerned   Professional Skills   Decision Making   On the job the individual needs to be able to: SB1. make appropriate decisions regarding the responsibilities of the job role   Plan and Organise   The user/individual on the job needs to know and understand how to: SB2. monitor efficient functioning of all activities SB3. plan and organise work to achieve targets and deadlines Customer Centricity   The user/individual on the job needs to know and understand how to: SB4. communicate with customers and other stakeholders in a courteous manner SB5. maintain effective work relationship   Problem Solving   The user/individual on the job needs to know and understand how to: SB6. identify trends/common causes for errors and suggest possible solutions to the supervisor / management SB7. identify and correct errors   Analytical Thinking   The user/individual on the job needs to know and understand how to: SB8. analyse best possible solutions (cost, time, effort, etc.) suited for operations   Critical Thinking   The user/individual on the job needs to know and understand how to: SB9. concentrate on task at hand and complete it without errors SB10. apply balanced judgments to different situations       Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack, every trainee should score a minimum of 60% of aggregate marks to successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.